This informational bulletin provides dealership personnel with information on flexible fuel vehicles (FFVs) and the usage of E85 fuel in GM vehicles.
full bulletin at NHTSA ↗2006 Chevrolet Silverado fuel system problems
severe 12 complaints filed with NHTSA · avg repair $1,200 · see fuel system across all vehicles →
Failure mileage
Complaints
12
Recalls
0
Avg fix
$1,200
2fires
When does it fail?
Of the 12 fuel system complaints filed for the 2006 Chevrolet Silverado, here's the actual mileage breakdown — failures cluster heaviest at 25,000-50,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Among the 11 model years of Chevrolet Silverado in our records for fuel system problems, this one ranks #2 by owner-complaint volume.
No new NHTSA fuel system complaint has been filed on this vehicle in over 17 years — the issue may be aging out of the active population.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering fuel system on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
INACCURATE FUEL GAUGE READINGS/REAR FLOAT ARM STUCK. UPDATED 03-01-07. UPDATED 3/15/10.
full bulletin at NHTSA ↗GENERAL MOTORS: MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED, INTERMITTENT DTC P0191, SLOW FUEL RAIL PRESSURE (FRP) DECAY, WIRING HARNESS CONNECTIONS, VOLTAGE FLUCTUATIONS/INTERRUPTIONS (FOLLOW CORRECTION INFORMATION BELOW). UPDATED 11/23/09.
full bulletin at NHTSA ↗GMC: FUEL GAUGE FLUCTUATION IN PARK OR NEUTRAL, CAUSING THE LOW FUEL LIGHT TO ILLUMINATE.
full bulletin at NHTSA ↗GMC: FUEL RAIL PRESSURE SENSOR PERFORMANCE DTC P0191. MAY SET DUE TO ACTUAL FUEL RAIL PRESSURE NOT DROPPING QUICKLY ENOUGH WHEN THE ENGINE IS SHUT OFF.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners of 2006 Silverados report a serious cluster of fuel system failures. Two separate narratives describe fires originating under the truck bed near the fuel tank—one at 3,800 miles while driving uphill, another at 15,000 miles after highway driving. Both vehicles burned completely.
Refueling problems appear as a distinct failure: at least one owner reported fuel spewing from the filler neck throughout a 30,000-mile ownership period, with the tank backing pressure out during fills. The dealer identified the need to reposition fuel system parts but did not complete repair.
Evaporative emissions and fuel pressure sensor defects are documented, with service engine lights recurring even after dealer code clearing. One owner's independent mechanic found the solenoid evaporation was modified and multiple components needed replacement.
Diesel-specific failures include vapor lock on the fuel filter causing complete shutdowns with loss of steering and brakes, and unexplained stalling during acceleration from moderate speeds. One owner's fuel filter clogged repeatedly despite dealer intervention 16 times.
Corrosion emerges as a recurring theme: fuel sender units failed from internal corrosion as early as 16,000 miles; fuel lines rusted and clogged injectors with debris; brake and fuel lines developed corrosion holes requiring $1,000+ replacement. Repair costs documented include $900 for fuel sender failure and over $1,000 for fuel and brake line replacement.
Same Chevrolet Silverado fuel system reports on nearby years: 2005
Failure modes owners describe
Fuel system fire
Smoke and flames originating from underneath the truck bed near the fuel tank area, resulting in total vehicle loss. Occurred while driving uphill on winding mountain road. One incident involved vehicle that had been idled then driven at highway speeds before fire was discovered.
When: At 3,800 miles in first incident; second incident at 15,000 miles
Symptoms owners cite: Smoke wisping from under cab/bed area; Visible flames from underneath truck; Engine stalled during first incident; Red warning indicators illuminated
Repairs/costs cited: Both vehicles totally burned; no repair possible
Fuel overflow during refueling
Gasoline spewing from fuel filler neck when refueling. Tank appeared pressurized, causing fuel to blow back during filling. Defect recurred every refueling attempt.
When: At 80,000 miles; recurring through 110,000 miles
Symptoms owners cite: Gasoline spurting from filler neck; Fuel pressure backing out during refuel; Required slow pump cycle (3 seconds pump, 10 seconds drain) to refuel safely
Repairs/costs cited: Dealer advised fuel system repositioning needed; repair not completed
Fuel vapor canister and evaporative system malfunction
Service engine light illuminating intermittently. Diagnostic inspection revealed modified solenoid evaporation and multiple related component issues. Defect persisted after dealer cleared code.
When: Mileage not specified in narrative
Symptoms owners cite: Service engine warning light intermittent illumination; Warning light recurred after dealer code clearing
Repairs/costs cited: Solenoid evaporation, canister evaporation, solenoid, gas cap, canister purge, fuel tank pressure sensor, and tubing replaced by independent mechanic
Recalls/TSBs owners mention: Manufacturer notified of failure
Diesel engine stall during acceleration
Engine dies for 2-3 seconds when driving at medium speed and flooring throttle. Dealers attributed to normal turbo lag, but owner reports Ford and Dodge diesel trucks do not exhibit this behavior. Problem reportedly present across multiple vehicles of same model.
When: No mileage specified
Symptoms owners cite: Engine stalls for 2-3 seconds during hard acceleration from 50 MPH; Turbo lag does not explain defect present across similar vehicles
Repairs/costs cited: Chip tuning and shift point adjustment reportedly resolves issue; no OEM repair documented
Recalls/TSBs owners mention: Dealers claimed normal turbo behavior
Fuel filter clogging and safety mode activation
Vehicle unexpectedly enters safety/limp mode, dropping speed from 60 MPH to 20 MPH without warning. Dealer repeatedly attributed to fuel filter and fuel type despite owner using consistent fuel grade throughout ownership. Problem persisted after filter changes and fuel additives.
When: At 42,700 miles
Symptoms owners cite: Vehicle drops to 20 MPH without warning; Cannot accelerate above 20 MPH; Enters limp/safety mode while driving
Repairs/costs cited: Dealer towed vehicle 16+ times, attributed to fuel filter despite repeated replacements not resolving issue
Fuel sender unit corrosion and failure
Fuel gauge reading empty despite full tank. Sender unit failed due to extensive internal corrosion. Multiple related components required replacement to repair.
When: At 16,000 miles
Symptoms owners cite: Fuel gauge shows empty with full tank; Gauge failure detected morning after refueling
Repairs/costs cited: Fuel sender unit replaced; extensive corrosion found requiring additional component replacement; repair cost $900
Fuel filter vapor lock on diesel
Diesel fuel filter experiencing vapor lock, causing complete engine shutdown. Occurred repeatedly (3+ times in one week) with minimal warning, creating loss of brakes and steering during operation.
When: No mileage specified
Symptoms owners cite: Vehicle shuts down without warning; Loss of hydraulic power (brakes and steering become very difficult); Near-miss collision incidents during failure events
Repairs/costs cited: No repair documented in narrative
Fuel line corrosion and clogging
Fuel line rusted, introducing corrosion particles into fuel system. Rust accumulated in injectors, requiring line replacement and injector cleaning. Separate incident of fuel and brake lines with corrosion holes.
When: At 24,147 miles for rust/clogging; timing not specified for corrosion holes
Symptoms owners cite: Fuel line corrosion visible; Injector clogging with rust particles; Fuel and brake lines corroded with holes
Repairs/costs cited: Fuel line and fuel injectors cleaned/replaced; brake and fuel lines replacement cost over $1,000
Diesel fuel filter defect
Fuel filter failure in diesel vehicle using appropriate fuel per manufacturer specifications. Requires owner-paid replacement.
When: Mileage not specified
Symptoms owners cite: Fuel filter failure
Repairs/costs cited: Fuel filter replacement required at owner expense
Synthesized from 12 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
Tl*the contact owns a 2006 Chevrolet silverado 3500. While driving 60 MPH, the vehicle goes into safety mode. The vehicle drops to 20 MPH without warning and cannot go any faster. The vehicle was towed to the dealer over sixteen times and they stated that the fuel filter was the cause of the failure, in addition to the type of fuel that was being used. The contact stated that he has been…
Had fuel system trouble with your 2006 Chevrolet Silverado?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the fuel system problem on the 2006 Chevrolet Silverado?
It's a meaningful issue. 12 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $1,200.
At what mileage does the fuel system typically fail?
Across the 9 complaints that reported odometer mileage, most fuel system failures cluster between 15,000 and 52,760 miles, with the median around 24,147. A quarter of owners report trouble before 15,000; a quarter make it past 52,760. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $1,200 for fuel system repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to fuel system?
No active recalls currently cover fuel system issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2006/Chevrolet/Silverado.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.